System 1: Orion Pulse 150i, pulse arc and resistance welder A sharpened 1mm tungsten electrode is used for all the operations. The stranded wire can be lap welded to the needle in a similar configuration to your soldered sample. This method requires welds to be made along the joint where the two components mate. The Orion Pulse 150i is set to Nano Mode at 2.0ws energy with sloped agitation enabled and standard ignition selected. Weld spots can be overlapped to form a continuous joint or the spots can be spaced out if desired. It is helpful to minimize any gap between the parts and ensure that the stranded wires are twisted together tightly before welding. The needle can also be butt welded to the stranded wire. In this attachment method the stranded wires are balled together at the end prior to attaching the needle. The size of the ball can be slightly controlled by raising or lowering the energy setting but we used the same setting for all the welds pictured. Once the strands have been balled the needle is held in line and attached to the ball. This method is fairly quick compared to the lap weld method and only requires 3 or 4 welds. Summary: The Orion Pulse 150i is an ideal solution for welding these samples. The touch screen user interface makes it easy for operators to quickly fine tune energy settings and find successful weld parameters.

• published: 14 Jul 2014
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